Absorbent article

ABSTRACT

An absorbent article including an absorbent core sandwiched between a liquid-permeable topsheet and a liquid-impermeable backsheet, and comprises a front portion, a back portion and a crotch portion located between the front portion and the back portion. The absorbent component includes a coherent area in only the front portion and the crotch portion of the absorbent article. The absorbent component includes oblong high basis weight areas of absorbent material alternating with oblong low basis weight areas of absorbent material. The high basis weight areas of absorbent material and the low basis weight areas of absorbent material not extending into the back portion of the absorbent article. The core comprises a conformance zone with absorbent material in the back portion of the absorbent article having 5-50% of the total average basis weight of the absorbent material in the absorbent component in the front portion of the absorbent article.

TECHNICAL FIELD

The disclosure pertains to an absorbent article comprising an absorbentcore which is sandwiched between a liquid-permeable topsheet and aliquid-impermeable backsheet. The absorbent core comprises an absorbentcomponent which is enclosed by a core cover.

BACKGROUND

In the field of disposable absorbent articles, such as disposableabsorbent diapers and pant-type articles, there is a general desire toprovide the absorbent articles with a snug and body conforming fit aswell as absorbency and leakage security. In addition, there is acontinuing need for improvements in particular with regard to reductionof material consumption as well as cost efficiency when manufacturingdisposable absorbent articles. There is also an increasing concern thatthe amount of material used in disposable absorbent articles is kept toa minimum from an environmental point of view. Hence, there is a desirefor disposable absorbent articles which require less raw material, withthe location of absorbent material in the article tailored towards theuser's anatomy and needs.

JP2019097898 discloses an absorbent core comprising a water-absorbingpolymer and a fibrous material forming high density portions.

SUMMARY

The present disclosure is based on the insight that an absorbent articlehaving improved fit and body conformance as well as good functionalitywith regard to absorbency, liquid distribution properties and leakagesecurity, may be achieved by a combination of selected features in anabsorbent core of the article.

The absorbent articles referred to herein are wearable and disposableabsorbent articles, for example in the form of open diapers, pantdiapers, belted diapers, incontinence garments, feminine hygienegarments and the like, as well as absorbent inserts which are worninside a support garment, such as a disposable or washable shell,support pant or ordinary underwear. The articles are used to absorb,distribute and store various types of body exudates while providing ahigh level of comfort and a sense of dryness to the wearer during use.

Disposable absorbent articles having good functionality, fit and bodyconformance may be achieved at least in part by the features of claim 1.Variations of the disclosure are set out in the dependent claims.

Disclosed herein is an absorbent article comprising an absorbent coresandwiched between a liquid-permeable topsheet and a liquid-impermeablebacksheet, the article having a longitudinal direction along a centrallongitudinal axis (y1) and a transverse direction along a centraltransverse axis (x1) extending perpendicular to the longitudinal axis.The absorbent article has a front end edge extending in the transversedirection and a back end edge extending in the transverse direction anda first side edge extending in the longitudinal direction and a secondside edge extending in the longitudinal direction. The absorbent articlecomprises a front portion, a back portion and a crotch portion locatedbetween the front portion and the back portion. The absorbent corecomprises an absorbent component enclosed by a core cover. The absorbentcomponent comprises a coherent area having an extension in thelongitudinal direction in at least the front portion and the crotchportion of the absorbent article and having an extension in thetransverse direction over a full width of the absorbent component insidethe core cover. The coherent area has a front edge and a back edge,wherein the absorbent component comprises oblong high basis weight areasof absorbent material alternating with oblong low basis weight areas ofabsorbent material. The high basis weight areas of absorbent materialand the low basis weight areas of absorbent material extending in thelongitudinal direction of the absorbent article at least in the frontportion, but not extending into the back portion of the absorbentarticle. The absorbent component in the crotch portion has 51-90% of thetotal average basis weight of the absorbent material in the absorbentcomponent in the front portion of the absorbent article. The corecomprises a conformance zone with absorbent material in the back portionof the absorbent article having 5-50% of the total average basis weightof the absorbent material in the absorbent component in the frontportion of the absorbent article.

Studies of spreading patterns have shown that an absorbent articleaccording to the present disclosure has an optimal distribution ofabsorbent material in order to obtain absorption where needed, whilestill providing a sustainable amount of absorbent material from anenvironmental perspective. This may specifically be the case for awearable absorbent article for babies and infants selected fromdisposable open diapers, pant diapers and belted diapers, inserts whichare worn inside a washable cover or support garment.

The absorbent component in the crotch portion may have 55-85%, such as60-80% of the total average basis weight of the absorbent material inthe absorbent component in the front portion of the absorbent articleand the conformance zone may have 15-45%, such as 20-40% of the totalaverage basis weight of the absorbent material in the absorbentcomponent in the front portion of the absorbent article

The total average basis weight in the front portion of the absorbentarticle may be 400-1100 gsm, such as 600-1000 gsm, such as 700-900 gsm.

The longitudinal extension of the absorbent component in the frontportion of the absorbent article may be 20-40% of the longitudinalextension of the core. The longitudinal extension of the absorbentcomponent in the crotch portion of the absorbent article may be 20-40%of the longitudinal extension of the core and the longitudinal extensionof the conformance zone may be 20-40% of the longitudinal extension ofthe core.

The oblong high basis weight areas may have a width of from 3 mm to 30mm, such as from 5 mm to 20 mm.

The oblong high basis weight areas may have a length of from 50 mm to400 mm, such as from 70 mm to 300 mm or from 100 mm to 200 mm.

The oblong high basis weight areas may extend in the longitudinaldirection substantially from the front edge to the back edge of thecoherent area in the front and crotch portion, but not extending intothe back portion of the absorbent article.

The oblong high basis weight areas may be arranged alternating in thetransverse direction with longitudinally extending low basis weightareas of absorbent material.

The oblong low basis weight areas may have a width of from 0.5 mm to 5mm.

The basis weight of the absorbent material in the oblong low basisweight areas may be less than 200 gsm, such as less than 100 gsm, suchas less than 50 gsm, such as less than 10 gsm.

The oblong low basis weight areas may have a length of from 50 mm to 400mm, such as from 70 mm to 300 mm or from 100 mm to 200 mm.

The oblong high basis weight areas may have, in combination, a width offrom 3 mm to 30 mm, such as from 5 mm to 20 mm and a length of from 50mm to 400 mm, such as from 70 mm to 300 mm or from 100 mm to 200 mm andmay be arranged alternating with low basis weight areas having a lengthequal to the length of the oblong high basis weight areas and a width offrom 0.5 mm to 5 mm, such as from 1.5 mm to 3 mm. The oblong high basisweight areas may have a length to width ratio of from 2 to 135, such asfrom 5 to 100 or from 15 to 70.

Oblong high basis weight areas are regions of the absorbent core inwhich absorbent material has been accumulated to provide absorption ofbody liquids where needed in the article and to provide rigidity to theabsorbent core.

Oblong high basis weight areas may have a greater thickness than theparts of the coherent area which are not occupied by oblong high basisweight areas, such as the oblong low basis weight areas. The thicknessin the oblong high basis weight areas may also be greater than thethickness of the conformance zone. The basis weight of the oblong highbasis weight areas is higher than the basis weight of the conformancezone.

The absorbent material in the oblong high basis weight areas have ahigher basis weight than the parts of the absorbent material in thecoherent area which are not occupied by the oblong high basis weightareas, such as the oblong low basis weight areas between the oblong highbasis weight areas. The absorbent material in the oblong high basisweight areas may have any combination of greater thickness, higher basisweight than the absorbent material in parts of the coherent area whichare not occupied by the oblong high basis weight areas.

The coherent area may be a primary absorption area of the absorbentarticle and is configured to provide a major part of the absorptioncapacity of the absorbent article. The largest absorption capacity ofthe absorbent core is in the front portion of the absorbent article ofthe present disclosure. The crotch portion of the absorbent articlecomprises a core part having less absorption capacity than the coreportion located in the front portion of the article. The coherent areatogether with the conformance zone may ascertain that the liquid whichreaches the absorbent article during use is safely absorbed, distributedand retained by the absorbent core, while at the same time providing asustainable amount of absorbent material in the absorbent article. Thecoherent area may have any suitable shape, such as rectangular shape,hourglass shape, etc.

The front, back and crotch portion of the absorbent article may eachform about a third of the length of the absorbent article. The absorbentcore may be in the crotch portion and extend at least partially into thefront and back portions of the absorbent article. The core may extendfurther into the front portion than into the back portion of theabsorbent article.

The core comprises an absorbent component enclosed by a core cover.Accordingly, an absorbent component is a part of the absorbent articlewhich is enclosed in a core cover.

The absorbent component may constitute all or part of the absorbentcore, as set out herein.

The absorbent component which is enclosed by the core cover, maycomprise both the coherent area of the absorbent core and a conformancezone or only the coherent area of the absorbent core. In the lattercase, a conformance zone may be provided as a separate component whichmay or may not be enclosed by a core cover.

An absorbent material composition may be the same in the coherent areaand in the conformance zone. The absorbent material may compriseabsorbent cellulose fibres, such as cellulose pulp fibers. The cellulosepulp fibers may be mixed with superabsorbent polymer material. Thesuperabsorbent polymer material may be in any suitable form as known inthe art, such as in the form of particles (including granules), fibers,flakes, etc.

In the coherent area of the absorbent component, the absorbent materialis interconnected such that there are unbroken fluid distribution pathswithin the absorbent material in the longitudinal direction from thefront edge of the coherent area to the back edge of the coherent area aswell as in the transverse direction from one side edge of the coherentarea to the other side edge of the coherent area. The coherent areaextends at least in the front portion and the crotch portion of theabsorbent article and extends in the transverse direction over the fullwidth of the absorbent component inside the core cover. Thus, fluidswhich are absorbed by the absorbent material in the coherent area of theabsorbent component can be efficiently distributed in the core componentboth in the longitudinal direction and in the transverse direction e.g.,under the action of capillary forces within the interconnected absorbentmaterial in the coherent area of the absorbent component. The coherentarea may be framed by absorbent material such that any channel thereinstops short from the front edge, the back edge, the first side edge andthe second side edge of the coherent area.

The width of the coherent area may decrease in a direction towards theback edge of the coherent area.

The absorbent component as disclosed herein may comprise a single corelayer.

The absorbent article as disclosed herein may comprise a single corelayer.

The back portion of the absorbent article comprises a conformance zonecomprising absorbent material. The conformance zone as disclosed hereinoffers efficient supplementary absorption of a relatively smaller amountof liquid which is not absorbed by the primary absorption material inthe coherent area of the absorbent core.

The conformance zone constitutes a secondary absorption area of theabsorbent article and generally has a considerably lower absorptioncapacity than the coherent area of the absorbent core. As disclosedherein, the conformance zone may have the absorbent material evenly orsubstantially evenly distributed in a uniform or substantially uniformlayer. The conformance zone may be formed from the same absorbentmaterial as the coherent area of the absorbent core.

In addition to providing a highly conformable back portion of theabsorbent article, the conformance zone saves material while stillproviding the absorbent article with appropriate absorbent capacitywhere needed. The conformance zone may be contiguous or non-contiguouswith the coherent area. A conformance zone is non-contiguous with thecoherent area if there is a distance between the back edge of thecoherent area and a front edge of the conformance zone. A non-contiguousconformance zone may alternatively be described as being detached,separate or independent from the coherent area. An area separating, i.e.an area located between, the coherent area and the conformance zoneprovides additional flexure to the absorbent structure. An areaseparating the coherent area and the conformance zone may traverse thewhole width of the absorbent component. The area may be substantiallyfree from absorbent material and may have a basis weight of less than200 gsm, such as less than 100 gsm, such as less than 50 gsm, such asless than 10 gsm. An area separating the coherent area and theconformance zone may have a width of 2-30 mm, such as 2-20 mm, such as5-10 mm.

The absorbent material in the conformance zone may be arranged toenhance the beneficial properties of the zone and may comprise any of,or a combination of, the following: The conformance zone may notcomprise areas being free from absorbent material. The absorbentmaterial in the conformance zone may not comprise individual clusters ofabsorbent material having a diameter larger than 10 mm. The absorbentmaterial in the conformance zone may have a basis weight gradient with alower basis weight near the transverse back edge of the absorbentcomponent. The absorbent material in the conformance zone may have abasis weight gradient with a higher basis weight in a centrallongitudinal area of the conformance zone. The conformance zone maycomprise a homogenous, or substantially homogenous mixture ofsuperabsorbent material and cellulose fibers.

The distribution of absorbent material in the conformance zone may beuniform or substantially uniform. The basis weight of the absorbentmaterial in the conformance zone may be substantially uniform.

The mixture of superabsorbents and cellulosic fibers in the conformancezone may have a basis weight coefficient of variation of at most 20%, asmeasured according to the method for measuring basis weight evennessprovided in this disclosure.

The conformance zone may be symmetrically orientated in relation to thelongitudinal axis and wherein the conformance zone has a triangularshape, a D shape, a W shape, a square or a rectangular shape.

As disclosed herein, the conformance zone may be symmetrically arrangedin relation to the longitudinal axis such that the conformance zone ismirror symmetric about the central longitudinal axis through theabsorbent article. The conformance zone may have a triangular shape, aD-shape, a W-shape or a rectangular shape, including a square shape.When triangular or D-shaped, the conformance zone has a shape whichnarrows in a direction towards the back end edge of the absorbentarticle such that a width of the conformance zone adjacent the back edgeof the coherent area of the absorbent core is greater than a width ofthe conformance zone adjacent the back end edge of the absorbentarticle. The width of the conformance zone may decrease continuously orin equally sized steps, as in a triangular conformance zone. The widthof the conformance zone may be constant in a front area closest to theback edge of the coherent area and decrease only at the back end of theconformance zone, as in a D-shaped conformance zone. The width of theconformance zone may be constituted by two or more rectangular sub-zonesof different width with a more forward sub-zone having a greater widththan a more rearward sub-zone or may have any other shape with a smallerwidth at the back part of the conformance zone than at the front part ofthe conformance zone.

A triangular or D-shaped conformance zone has been found to be inagreement with spreading patterns observed in user tests, wherein meansfor liquid absorption has been shown to be primarily needed in a centrallongitudinal area of the back portion of the absorbent core, with lessor no absorption capacity needed near the longitudinal sides of the backportion of the absorbent core.

The back edge of the coherent area may be a non-linear edge and may haveat least one aberration, such as one or more protrusions extending awayfrom a straight base line or a baseline having an even curvature. Theback edge of the coherent area may have the form of a baseline fromwhich evenly distributed protrusions extend in a direction toward theback end edge of the absorbent article.

The protrusions of the back edge of the coherent area may be in the formof semi-circles extending longitudinally away from the front end edge ofthe absorbent article and towards the back end edge of the absorbentarticle.

The coherent area may comprise at least one area which is free orsubstantially free from absorbent material. An area which is free ofsubstantially free from absorbent material may be an opening or achannel arranged in the coherent area.

The core cover may have an upper side and a lower side and the absorbentcomponent may comprise a sealing arrangement joining the upper and lowersides of the core cover. The sealing arrangement may comprise at leastone sealed channel extending in the longitudinal direction of theabsorbent article, the sealed channel being free or substantially freefrom absorbent material. The sealed channels have seals extendingtherein, the seals joining the upper and the lower side of the corecover within the sealed channels.

The coherent area of the absorbent component may comprise two sealedchannels in the crotch portion of the absorbent article, the channelsextending in the longitudinal direction of the absorbent component. Acentral segment may be defined in the absorbent component between thesealed channels. The two sealed channels may be symmetrically arrangedon each side of the central longitudinal axis with the central segmentextending in the longitudinal direction between the sealed channels.

The sealed channels may be permanent channels, implying that the sealsjoining the upper and lower sides of the core cover remain unbrokenduring normal use of the absorbent article. Alternatively, the seals maybe temporary seals which are released as the core absorbs fluid andswells.

Permanent seals in the sealed channels restrain the cover material andprevent the absorbent material in the absorbent component from expandinginto and closing the sealed channels upon wetting of the absorbentcomponent. The channels may be free from absorbent material.

Temporary seals break open under the influence of fluid and/or theforces acting on the seals as the absorbent material absorbs fluid andswells. The freed channels may then serve as auxiliary expansion space,allowing the absorbent material to swell and expand laterally into thechannels.

Oblong high basis weight areas in the coherent area may at least partlyextend along the sealed channels. This will always be the case foroblong high basis weight areas being arranged in the crotch portion ofan absorbent article as disclosed herein and having sealed channelsarranged in the crotch portion.

The absorbent article may further comprise two side seams being arrangedalong longitudinal side edges of the absorbent component. In a coherentarea having two sealed channels, a center segment having a first widthis defined in the absorbent component between the sealed channels, andtwo side segments each having a second width are defined in theabsorbent component outside each channel seal between each channel sealand a corresponding one of the side seams.

The absorbent component in the crotch portion may be configured so that33 to 41 weight % of the absorbent material is in the center segment and25 to 33 weight % of the absorbent material is in each one of the sidesegments.

When defining that the total amount of absorbent material in a centersegment located between two sealed channels is generally equal to, orgreater than the total amount of absorbent material in each one of theside segments, is meant that the total weight of the absorbent materialin the center segment is generally equal to, or greater than, the totalweight of the absorbent material in each one of the side segments.

The provision of sealed channels in the absorbent component contributesto improving fit, comfort and function of the absorbent article in itswet condition. The crotch portion of the absorbent article, and inparticular a segment between two sealed channels, may be configured todevelop a higher stiffness as compared with the remaining parts of theabsorbent core. There is a well-known problem with sagging in the crotchportion of an absorbent article as the article absorbs liquid whichaccumulates in the crotch portion. The sagging problem will graduallyincrease as the amount of liquid absorbed by the article increases. Anabsorbent article, as disclosed herein and being provided with at leasttwo permanently sealed channels, may be constructed so that thestiffness in the segment of the absorbent component which is locatedbetween the sealed channels increases gradually with the amount ofliquid absorbed by the article. Initially, when only a small amount ofliquid has been absorbed, the problem with sagging is negligible, andtherefore the stiffness in the center segment does not need to be high.As the amount of absorbed liquid increases, the problem with saggingincreases proportionally, and so a higher stiffness in the centersegment is desirable to counteract the weight of the absorbed liquid inthe crotch portion.

Furthermore, according to the present disclosure, absorbent sidesegments arranged between side seams of the absorbent component andsealed channels may not, or at least not to any substantial extent,increase its stiffness in wet condition. The absorbent side segmentswill ensure that the total absorbent capacity in the crotch portion issufficient while remaining relatively soft and pliable, as compared tothe stiffened portion or portions located between sealed channels.According to the present disclosure, an absorbent article may beobtained having a reduced tendency for sagging while at the same timehaving sufficient absorption capacity in the crotch portion and alsobeing comfortable to wear for the user.

The core cover enclosing a central segment located between twopermanently sealed channels defines and limits the expansion space forthe absorbent material in the central segment. Thereby, the stiffness ofthe central segment will increase as the absorbent material absorbsliquid and swells during use of the article. In the absorbent articlesas disclosed herein, it is not necessary that the expansion space iscompletely closed around the central segment or segments between thesealed channels in order to achieve the stiffening effect, only that theswelling of the absorbent material in the central segment or segments isrestricted, at least in the transverse direction of the absorbentarticle. The ends of a central segment may be open such that fluid maypass in the longitudinal direction out of the central segment.

The absorbent article may comprise leg elastic elements extending alongall or a part of each longitudinal side edge of the absorbent article.If one or more longitudinally extending channel is provided in thecrotch portion of the absorbent article, the leg elastic elements mayhave a greater length in the longitudinal direction of the absorbentarticle than the length of the one or more longitudinally extendingchannel.

The leg elastic elements may extend in the longitudinal direction of thearticle in the crotch portion of the absorbent article and in part ofthe front portion and/or part of the back portion of the absorbentarticle. The leg elastic elements may have a greater extension in theback portion than in the front portion.

The leg elastic elements may cooperate with features of the absorbentcomponent such as the oblong high basis weight areas and the optionalsealed channels as disclosed herein, to promote shaping and fit of theabsorbent article during use.

A ratio of a width of a center segment of the absorbent component asmeasured in the transverse direction between two sealed channels and adistance in the transverse direction between the leg elastic elementsmay be from 0.10 to 0.30, from 0.15 to 0.25 or from 0.18 to 0.22.

The article may comprise a waist elastic feature located in the backportion at the back end edge of the absorbent article. A waist elasticfeature, together with leg elastic elements and the absorbent componentmay cooperate with the arrangement of a stiffening central segmentlocated between two sealed channels and two side segments to provideimproved fit of the article during use. In addition to or instead of awaist elastic feature in the back portion of the absorbent article, awaist elastic feature may be located in the front portion of theabsorbent article. Waist elastic features may extend only partly alongthe front and/or the back end edge or may extend the full length of thefront and/or the back end edge, i.e. from the first side edge to thesecond side edge of the absorbent article.

A core cover as disclosed herein may be formed by a separate upper corecover layer forming the upper side of the core cover and a separatelower core cover layer forming the lower side of the core cover, theupper and lower core cover layers together enclosing the absorbentcomponent. A sealing arrangement may be provided for joining the upperand lower sides of the core cover at the edges of the core component.The disclosure is not limited to core covers comprising two separatecore cover layers. The core cover may be formed from a single materiallayer. In such case the absorbent component may be enclosed by one corecover layer which is wrapped around the absorbent component or which isformed as a tubular structure into which the absorbent component isinserted. Furthermore, the core cover may be made from more than twocore cover layers. The core cover may be sealed only in the longitudinaldirection of the absorbent article, leaving the core cover open in botha front end of the core cover and in a back end of the core cover.Alternatively, the core cover may be sealed at one or both of the frontend and the back end of the core cover. In the latter case, theabsorbent component is completely enclosed inside the core cover.

In the absorbent article as disclosed herein, both the upper core coverlayer and the lower core cover layer may be liquid-permeable coverlayers together forming a liquid permeable core cover. The upper corecover layer and optionally also the lower core cover layer may be ahydrophilic layer. Hydrophilicity may be accomplished by incorporatinginherently hydrophilic fibers in the core cover layer, such as cellulosefibers or regenerated cellulose fibers, e.g. wood pulp fibers, cotton,flax, hemp, viscose, etc. as known in the art. Hydrophilicity may alsobe accomplished by treating inherently hydrophobic materials such aspolymeric films and fibers, e.g. polyolefins such as polyethylene andpolypropylene, polyesters, etc. to render them hydrophilic and wettable.

The lower core cover layer may be liquid impermeable and/or hydrophobic

The basis weight of the core cover material may be in the range of from5 g/m² to 20 g/m².

The core cover material may be made of thermoplastic polymer material,such as polyolefin, polyesters, polyamide and combinations thereof. Thecore cover material may be nonwoven material. The nonwoven material maybe made of thermoplastic polymer material fibers or filaments. Thenonwoven layer may be formed by any of a variety of different processes,such as spunbonding, airlaying, meltblowing or bonded carded webformation processes. The nonwoven layer may be made of co-formed laminaof nonwoven materials such as an SMS (spunbond/meltblown/spunbond)nonwoven material or an SS (spunbond/spunbond) nonwoven material. Thethermoplastic polymer materials in the nonwoven layer may bepolypropylene or bicomponent fibers of polypropylene and polyethylene,or of a combination of such materials.

As set out herein, the absorbent article may comprise a single corelayer.

An absorbent component as disclosed herein may be constituted by onesingle absorbent component layer which is wrapped in a core cover havingan upper side and lower side.

Absorbent components comprising two or more layers are also contemplatedfor the absorbent cores as disclosed herein.

The absorbent component may have a rectangular shape. A rectangularabsorbent component may have the advantage of being easy to manufactureand enclose by a core cover.

The absorbent component may comprise a mixture of absorbent cellulosefibers, such as cellulose pulp fibers (pulp material) and superabsorbentpolymer material in the form of particles, granules, fibers, flakes,etc. The absorbent material in the absorbent component, at least in thecrotch portion, may be constituted by 50-100 weight % superabsorbentmaterial and 0-50 weight % pulp material, or 70-100 weight %superabsorbent material and 0-30% pulp material.

The composition of the absorbent material may be the same in thecoherent area and in an optional conformance zone. Hence, a mixture ofsuperabsorbent material and pulp material may be the same in thecoherent area and in the conformance zone.

The total absorbent capacity per cubic centimeter of the coherent areaof the absorbent component in dry condition may be at least 15 g/cm³, orat least 25 g/cm³ or at least 35 g/cm³.

The pulp material in the coherent area of the absorbent component mayhave a basis weight which is in the interval of 50-400 g/m² and thesuperabsorbent material may have a basis weight which is in the intervalof 100-900 g/m².

The thickness of the coherent area of the absorbent component in drycondition, measured with an applied pressure of 0.5 kPa, may be in therange of from 1.0 to 5.5 mm or from 2.0 to 4.5 mm. A representative meanvalue may be obtained by measuring on several parts of the absorbentcomponent.

The absorbent component may be formed using an air forming process, suchas an air forming process carried out on an air forming drum, alsoreferred to as a vacuum forming drum. The air forming drum operates byapplication of internal suction in the forming drum to draw flows of airsuspended absorbent material into forming molds arranged on the surfaceof the forming drum.

The forming drum may have several forming molds arranged on the outersurface into which the absorbent material is deposited for continuouslyforming absorbent components. The shape and size of the forming moldsdetermine the shape and size of the absorbent components. Each formingmold has a foraminous air permeable bottom on which the air suspendedabsorbent material is collected and accumulated as the air is drawn offinto the interior of the forming drum. The amount of material depositedin different parts of the mold may be controlled by controlling the airflow through the foraminous bottom. To this end, the foraminous bottomof the mold may have different air permeability in different portions ofthe mold which may be accomplished by arranging masking plates indifferent parts of the mold and/or by shaping the foraminous bottom tocreate a mold with varying depth, corresponding to an absorbentcomponent having different thickness in different parts. A first part ofthe mold may be arranged to produce the coherent area of the absorbentcomponent as set out herein. The bottom of the first part of the moldmay then comprise grooves corresponding to where oblong high basisweight areas of accumulated material are to be formed which will formoblong high basis weight areas in the coherent area of the absorbentcomponent and/or one or more blocked areas where channels are to beformed in the absorbent component. A second part of the mold is arrangedto produce the conformance zone and has a blocking plate having openingsarranged therein. The presence of blocking plate(s) in the second partof the mold serves to decrease the air permeability in this area of themold and causes a greater part of the air flow and concomitantly agreater part of the air suspended absorbent material to be drawn towardsand collected in the first part of the forming mold. It may also createan area substantially free from absorbent material vertically separatingthe coherent area and the conformance zone if this is desired.

The disclosure may be varied within the scope of the appended claims.For example, the materials and dimensions used for the different layersforming an absorbent article as disclosed herein may be varied, asindicated above. The absorbent article may further include any usefulcomponent or feature as known in the art such as fluid acquisition anddistribution components, leg elastics, standing gathers, crotch andwaist elastics, side panels, fastening systems, wetness indicators, skincare agents, disposal means, etc., as known in the art and depending ofthe type of absorbent article intended.

BRIEF DESCRIPTION OF THE DRAWINGS

The absorbent articles as disclosed herein will be further explainedhereinafter with reference to the appended drawings wherein:

FIG. 1 shows a view from above of an absorbent article in the form of adiaper;

FIGS. 2A-2G show different core configurations;

FIG. 3 shows a cross-section taken along the line III-III in FIG. 2C;

FIG. 4 shows a cross-section taken along the line IV-IV in FIG. 2C; and

FIG. 5 shows a cross-section taken along the line V-V in FIG. 2C.

DETAILED DESCRIPTION

Different aspects of the present disclosure will be described more fullyhereinafter with reference to the enclosed drawings. The embodimentsdisclosed herein can, however, be realized in many different forms andshould not be construed as being limited to the aspects set forthherein.

It is to be understood that the drawings are schematic and thatindividual components, such as layers of material are not necessarilydrawn to scale.

With initial reference to FIG. 1 , there is shown an absorbent article 1in the form of a baby diaper. The absorbent article 1 is shown in FIG. 1in an unfolded and flat state with all elastic elements in an extendedstate.

The absorbent article 1 is seen from the surface which will be facing awearer's body when the article is being worn and comprises aliquid-permeable topsheet 3, a liquid-impermeable backsheet 4 and anabsorbent core 5 which is sandwiched between the topsheet 3 and thebacksheet 4. The topsheet 3 is arranged at the inner or wearer-facingsurface of the absorbent article 1, whereas the backsheet 4 is arrangedat the outer or garment-facing surface of the absorbent article 1.Furthermore, as illustrated in FIG. 1 , both the topsheet 3 and thebacksheet 4 may extend laterally outside of the absorbent core 5 alongthe entire perimeter of the absorbent article 1. Alternatively, thetopsheet 3 and the backsheet 4 may be generally coextensive with theabsorbent core 5 or only one of the topsheet 3 and the backsheet 4 mayextend outside the perimeter of the absorbent core 5. It is alsoconceivable that the topsheet 3 and the backsheet 4 extend outside ofthe absorbent core only along parts of the perimeter of the absorbentarticle, such as only along the side edges or only along one or both endedges or along the side edges and only one of the end edges.

The absorbent core 5 shown in FIG. 1 has a rectangular design. However,as set out herein, the disclosure is not limited to this design and itis to be understood that the absorbent core may have any useful shapewithin the scope of the invention.

The topsheet 3, backsheet 4 and the absorbent core 5 may consist of anymaterials suitable for their purposes, as will be discussed in furtherdetail below.

As shown in FIG. 1 , the absorbent article 1 has a longitudinaldirection along a central longitudinal axis y1 and a transversedirection along a central transverse axis x1, which is perpendicular tothe longitudinal axis y1. Furthermore, the absorbent article 1 may bedefined as being divided into a front portion 6 having a length l₂, aback portion 7 having a length l₃ and a crotch portion 8 having a lengthl₁. Each of the front, back and crotch portion 6, 7, 8 of the absorbentarticle may form about a third of the length of the absorbent article 1.

The front portion 6 has a front waist edge constituting a front end edge19 of the absorbent article 1 and the back portion 7 has a back waistedge constituting a back end edge 21 of the absorbent article 1. Legedges are formed by longitudinally extending side edges 32,33 of theabsorbent article 1. The front portion 6 is the part of the absorbentarticle which is intended to be oriented in a direction towards thebelly of the wearer during use of the absorbent article 1 and the backportion 7 is the part of the absorbent article which is intended to beoriented in a direction towards the buttocks of the wearer.

The absorbent article 1 in FIG. 1 is an open-type diaper having frontgripping tabs 23, 24 extending from the side edges 32, 33 at the frontend edge 19 of the absorbent article 1 and back fastener tabs 25, 26extending from the side edges 32, 33 at the back end edge 21 of theabsorbent article 1. When applying the absorbent article 1 to a wearer,the back fastener tabs 25, 26 are brought forward towards the wearer'sbelly and are attached with fastener elements 27, 28, such as hook-typefastener elements onto mating fastener elements such as loop-typefastener elements which are provided on the outer surface of the frontportion 6 of the absorbent article 1.

It is to be understood that male fasteners, such as hook-type fastenersmay instead be placed at the front of the article while female fastenersmay be placed at the back of the article. Furthermore, the fasteningarrangement may differ from that shown in the Figs. and may be of anyuseful kind as known in the art. Accordingly, fastener belts, girdles,adhesive fastening systems, etc. may be used. It should also be notedthat the fastening system is optional to the absorbent article 1, as thearticle may be designed for use as an absorbent insert, worn inside apair of supportive pants or ordinary underpants. Such articles may beprovided with fastening adhesive arranged on the outer surface of thebacksheet, to allow the article to be fastened inside the pants.Furthermore, the absorbent article may be a pant-type article which isprovided in a pre-assembled configuration, with closed side seams. Sucharticles may nevertheless be provided with a fastening system, to allowthe article to be opened and reclosed.

The absorbent core 5 comprises an absorbent component 50 which issandwiched between an upper core cover side 11 and a lower core coverside 12. The core cover is a component of the absorbent article 1 whichis provided in addition to the topsheet 3 and the backsheet 4. Theabsorbent component 50 has a front edge 52 and a back edge 22.

The absorbent component 50 comprises a coherent area 51 which isdisposed forward in the absorbent article 1 with a forward part of thecoherent area 51 being located in the front portion 6 and a rearwardpart of the coherent area 51 being located in the crotch portion 8 ofthe absorbent article 1. The coherent area 51 has a front edge 52, aback edge 53, a first side edge 29 and a second side edge 38. As can beseen in FIG. 1 , the width of the absorbent core 5 is the same as widthof the absorbent material inside the core cover 11, 12 of the absorbentcomponent 50 within the coherent area 51. This width is defined by thewidth of the coherent area 51 between the first side edge 29 and thesecond side edge 38. The coherent area 51 is coherent withinterconnected fluid distribution paths running all the way from thefirst side edge 29 of the coherent area 51 to the second side edge 38 ofthe coherent area 51 implying that liquid may travel along unbrokenpaths from one side edge 29 to the other side edge 38 of the coherentarea 51. The back portion 7 of the absorbent article 1 comprises aconformance zone 55 which is placed behind the coherent area 51 as seenin a direction towards the back end edge 21 of the absorbent article 1.

The coherent area 51 of the absorbent core 5 comprises high basis weightareas 60, the high basis weight areas 60 may be oblong as in FIG. 1 ,extending in the longitudinal direction within the material in the frontportion of the coherent area 51 towards the back end edge 21 of theabsorbent article 1. The oblong high basis weight areas 60 are regionsof the absorbent core 5 in which absorbent material has been accumulatedsuch that longitudinally extending striations are formed in the materialof the coherent area 51. The number of oblong high basis weight areas inFIG. 1 is 11, but may be from 3 to 30 oblong high basis weight areas 60.

The basis weight of the absorbent material in the oblong high basisweight areas 60 may 650 gsm and below 1050 gsm. The oblong high basisweight areas 60 have a width of 3 to 30 mm, such as 5 to 20 mm. The highbasis weight areas 60 are delimited in the transversal direction by lowbasis weight areas 54 of absorbent material. The oblong low basis weightareas 54 may have a width of from 0.5 mm to 5 mm. The basis weight ofthe absorbent material in the oblong low basis weight areas may 200 gsmor less.

The length of the oblong high basis weight areas 60 and the oblong lowbasis weight areas 54 may be from 50 to 400 mm, such as from 70 to 300mm or from 100 to 200 mm. In the embodiment shown in FIG. 1 , the oblonghigh basis weight areas 60 and the intervening oblong low basis weightareas 54 are arranged only in the front portion 6 of the absorbentarticle and have a length in the order of 70 mm. As disclosed herein,the oblong high basis weight areas 60 and the oblong low basis weightareas 54 may in addition to being arranged in the front portion 6 of thearticle 1 be arranged also in the crotch portion 8 of the article, butnot extend into the back portion of the absorbent article 1.

The conformance zone 55 as shown in FIG. 1 is contiguous with thecoherent area 51 of the absorbent component 50. The V-shaped area 57 hasits base arranged from the back edge 53 of the coherent area 51 and itstip 59 arranged on the central longitudinal axis y1 of the absorbentarticle and facing the back end edge 21 of the absorbent article 1.

The conformance zone 55 of the article 1 illustrated in FIG. 1 comprisesabsorbent material and the zone may be without gaps or areas being freefrom absorbent material. The absorbent material in the conformance zone55 may have a uniform or substantially uniform distribution of absorbentmaterial. The absorbent material in the conformance zone 55 may notcomprise individual clusters of absorbent material having a diameterlarger than 10 mm. The basis weight of the absorbent material in theconformance zone 55 may be substantially uniform. The conformance zone55 may comprise a substantially homogenous mixture of superabsorbentmaterial and cellulose fibers. The mixture of superabsorbents andcellulosic fibers in the conformance zone may have a basis weightcoefficient of variation of at most 20%, as measured according to themethod for measuring basis weight evenness provided in this disclosure.

In the absorbent article 1 as shown in FIG. 1 , the conformance zone 55is enclosed by the upper and lower sides of the core cover 11, 12 andforms part of the absorbent component 50. The planar shape and size ofthe absorbent component is defined by the planar shape and size of thecore cover. As disclosed herein, the core cover may be formed by twoseparate sheets of material which are sealed at least along theirlongitudinally extending side edges and optionally also along one orboth of the transversely extending end edges. Alternatively, the corecover may be formed by a bi-folded sheet of material which may be foldedin the longitudinal direction and sealed at least along the side edgeswhich are opposite to the fold.

The coherent area 51 of the absorbent component 50 which is shown inFIG. 1 comprises oblong high basis weight areas 60 extending in thelongitudinal direction in a front portion of the coherent area 51.

The absorbent component 50 in the crotch portion 6 has 51-90% of thetotal average basis weight of the absorbent material in the absorbentcomponent 50 in the front portion 6 of the absorbent article 1. Theconformance zone 55 has 5-50% of the total average basis weight of theabsorbent material in the absorbent component 50 in the front portion 7of the absorbent article 1.

The absorbent component 50 which is shown in FIG. 1 is formed with twolongitudinally extending and generally straight sealed channels 9,10 inwhich the upper core cover side 11 is joined to the lower core coverside 12 by seals extending along the sealed channels 9,10. The seals maybe provided as bond lines consisting of bonding elements arranged in abond pattern. A width of each bond line may be less than a width of thecorresponding sealed channel 9, 10 in which the bond line is arranged.Thereby, a slack is formed in the core cover material between the edgeof the bond line and the edge of the sealed channel in which the bondline is placed. Such slack may be provided to allow expansion room forthe absorbent material arranged on either side of the bond lines. Theslack may be smaller on the inner side of each sealed channel 9,10 whichis facing towards the centre of the absorbent article, and larger on theouter side of each sealed channel 9,10 which is facing towards the sideedges of the absorbent article 1.

As set out herein, the disclosure is not limited to a core wrapcomprising two core cover layers. The core cover may be of one singlematerial layer. The absorbent component may be enclosed by one corecover layer folded in two, or enclosed by a continuous core cover sheet,thereby providing upper and lower core cover sides for wrapping theabsorbent component.

The upper core cover side 11 and the lower core cover side 12 may beattached to each other by any useful means as known in the art, forexample, by thermo-mechanical bonding, such as thermo-sealing,ultrasonic bonding, an adhesive or adhesives, stitching or the like, orcombinations of the same.

The sealed channels 9, 10 constitute sections of the absorbent component50 which are free from absorbent material. Absorbent free channels maybe obtained by manufacturing the absorbent component 50 using a matforming process during which absorbent material is omitted from theareas which correspond to the sealed channels 9,10. In this manner, noabsorbent material will be present in the sealed channels 9,10. Thepresence of absorbent material in the sealed channels 9,10 maynegatively influence the strength of the seals between the upper andlower core cover sides 11, 12 and should be avoided.

As shown in FIG. 1 , the absorbent component 50 may be divided into acentral segment 13 located in the crotch portion 8 between the sealedchannels 9,10 and two side segments 14 a, 14 b. The sealed channels 9,10are consequently configured so that they separate the three segments 13,14 a, 14 b from each other in the crotch area 8.

The absorbent component 50 may be generally rectangular and may comprisetwo generally straight sealed channels 9, 10 which extend generallyparallel to the longitudinal axis y1. The seals joining the upper andlower core cover sides 11, 12 have a corresponding first channel sealingwidth w1 and a second channel sealing width w2. The disclosure is notlimited to a rectangular absorbent component 50 and generally straightsealed channels 9, 10, i.e. other geometrical configurations may beused.

Furthermore, the central segment 13 is defined in the absorbentcomponent 50 between the sealed channels 9, 10. The two side segments 14a, 14 b are defined in the absorbent component 50 outside each sealedchannel 9, 10. More precisely, the first side segment 14 a is positionedbetween the first sealed channel 9 and a first side seam 15, whereas thesecond side segment 14 b is positioned between the second sealed channel10 and a second side seam 16. The side seams 15, 16 are configured forjoining the upper core cover side 11 to the lower core cover side 12,suitably by means of ultrasonic welding or other relevant technologiesas described above with reference to the seals joining the upper coverside 11 and the lower cover side 12 in the sealed channels 9, 10.

The sealed channels 9, 10 may be permanently sealed channels 9, 10 asdisclosed herein, implying that the central segment 13 may swell andform a stiffening element between the sealed channels 9, 10.Alternatively, the sealed channels may be temporarily sealed channels9,10 in which the seals arranged in the sealed channels 9,10 between theupper and lower core cover sides 11, 12 break when the core 5 absorbsliquid and swells, so that the absorption material may expand into thereleased channels. Furthermore, the side seams 15, 16 extend along eachside of the absorbent component 50, inward of and along a first sideedge 17 and a second side edge 18 of the absorbent component 50.

As mentioned, the length l₁ of the crotch portion 8 may be equal to thelength of the sealed channels 9, 10, i.e. the sealed channels 9, 10 maybe arranged only in the crotch portion 8. However, the side seams 15, 16may not just be positioned along the crotch portion 8 but may alsoextend into the front portion 6 and/or the back portion 7 as set out inmore detail below.

The absorbent article 1 in FIG. 1 also has leg elastic elements 30,31extending along each longitudinal side edge 32,33 of the absorbentarticle 1. The leg elastic elements 30,31 have a greater length in thelongitudinal direction than the length of the sealed channels 9, in thelongitudinal direction. Accordingly, the leg elastic elements have anextension not only in the crotch portion 8 but also in a part of thefront portion 6 and the back portion 7. The leg elastic elements 30, 31have a greater extension in the back portion 7 than in the front portion6, as seen in FIG. 1 .

The absorbent article 1 also has a waist elastic element 34 located inthe back portion 7 close to the back end edge 21 of the absorbentarticle 1. It is to be understood that also the front end edge 19 may beprovided with waist elastic, if desired.

The leg elastic elements and the waist elastic element are optionalfeatures of an absorbent article as disclosed herein.

As disclosed herein, the absorbent component 50 is formed with a sealingarrangement which is constituted by the two sealed channels 9, 10 andthe two side seams 15, 16. The sealing arrangement is configured sothat, in the crotch portion 8, the absorbent component 50 is dividedinto a central segment 13 and two side segments 14 a, 14 b.

As disclosed herein, the absorbent material may comprise a mixture ofcellulose pulp material and superabsorbent material. The absorbentcomponent 50 may be configured so that the total amount of absorbentmaterial of the central segment 13 between the sealed channels 9, 10 isgenerally equal to or greater than the amount of absorbent material ineither one of the side segments 14 a, 14 b between each sealed channel9, 10 and the corresponding side seam 15, 16. In an embodiment havingpermanently sealed channels 9,10, this means that the available spacefor expansion of the absorbent material in the central segment 13, asthe absorbent article 1 becomes wet as it absorbs liquid during use, isless than a corresponding available expansion space for each sidesegment 14 a, 14 b. This will lead to a situation in which the centralsegment 13 will be stiffer than the side segments 14 a, 14 b when theabsorbent article is in its wet condition. The stiffened central segment13 counteracts the tendency of the wet article to sag and hang down inthe crotch portion 8.

The expression “generally equal” as used above for describing the amountof absorbent material in the central segment 13 as compared with theside segments 14 a, 14 b should be understood as allowing for slightvariations in the amount of absorbent material in the order ofapproximately ±5% in any part of the crotch portion 8.

A width of the central segment 13 may be defined between the sealedchannels 9, 10 and a width of the absorbent component 50 may be definedbetween the first and second side edges 17, 18 of the absorbentcomponent 50. The ratio of the width of the central segment 13 and thewidth of the absorbent component 50 may be in the range of from 0.25 to0.45.

The width of the coherent area 51 is equal to the width of the absorbentcomponent 50 between the first and second side edges 17, 18 of theabsorbent component 50.

As disclosed herein, various types of materials may be used for theabsorbent article 1. The topsheet 3 which is arranged to face the wearerof the absorbent article 1 when the article is being worn may compriseor consist of a fluid permeable nonwoven fabric, film, mesh or foam. Thetopsheet may be made from thermoplastic material, such as thermoplasticsynthetic fibers, film or netting. The topsheet 3 may be sufficientlyliquid-permeable to allow discharged body fluids to penetrate throughthe thickness of the topsheet 3. Also, the topsheet 3 may suitably bemanufactured from a material which is compliant and soft-feeling to theskin of the wearer. The topsheet 3 may consist of a single layer or mayhave a laminate structure comprising a plurality of layers, for example,two or more layers. The layers may be made of the same material, or someor all of the layers may be made of different materials.

The layer of the topsheet 3 or, for the case of a laminate structure,one, some, or all layers of the topsheet may be made of a single web ofmaterial or may have portions made of different materials, e.g., withindifferent parts of the wearer-facing surface of the topsheet.

The layer of the topsheet 3 or, for the case of a laminate structure,one, some or all layers of the topsheet may be a nonwoven material, aperforated plastic film, a plastic or textile mesh, or a liquidpermeable foam layer. The layer of the topsheet 3 or, for the case of alaminate structure, one, some or all of the layers of the topsheet maybe, for example, a hydrophilic, non-apertured nonwoven web of fibers,such as natural fibers, e.g., cotton or pulp fibers, synthetic fibers,e.g., polyester or polypropylene fibers, or a combination of thesefibers. The topsheet may have a basis weight in the range of 8-40 g/m².However, the disclosure is not limited to topsheets having this basisweight.

Furthermore, the backsheet 4 may be constituted by a liquid-impermeablelayer such as a polymeric film, for example a film of polyethylene orpolypropylene. The backsheet 4 may be breathable. The materials whichmay be used for the backsheet 4 include thin and flexible fluidimpermeable plastic films, or fluid impermeable nonwoven materials,fluid impermeable foams and fluid impermeable laminates. The backsheet 4may be formed by a single layer, but may alternatively be formed by amulti-layered structure, i.e. a laminate, wherein at least one layer isfluid impermeable. Furthermore, the backsheet 4 may be elastic in anydirection. Furthermore, the backsheet 4 may have a laminate structurecomprising a liquid barrier sheet and a nonwoven layer arranged on topof each other (not shown in detail in the drawings), wherein thenonwoven layer is arranged at an outer side away from the wearer of theabsorbent article 1 when worn.

The nonwoven layer may be made of thermoplastic polymer material fibersor filaments. The nonwoven layer may be formed by any of a variety ofdifferent processes, such as spunbonding, airlaying, meltblowing orbonded carded web formation processes. The nonwoven layer may be made ofan SMS (spunbond/meltblown/spunbond) or SS (spunbond/spunbond) nonwovenmaterial of polypropylene or bicomponent fibers of polypropylene andpolyethylene, or of a combination of such materials. The nonwoven layermay have a basis weight in the range of 5-40 g/m².

The liquid barrier sheet may be made of a plastic material, for examplea thermoplastic film material, and/or a nonwoven material. For example,the liquid barrier sheet may be formed as a plastic layer, e.g., athermoplastic layer, or a plastic film, e.g., a thermoplastic film.Forming the liquid barrier sheet of a plastic material, such as athermoplastic film material, allows for a particularly good printabilityof the liquid barrier sheet. The liquid barrier sheet may also containpaper fibers. The liquid barrier sheet may be a liquid impermeable,breathable or non-breathable layer. The liquid barrier sheet may consistof a single layer or have a laminate structure with a plurality oflayers, e.g., two or more layers, three or more layers, or four or morelayers. The layers of the liquid barrier sheet may be laminated, bondedor attached to each other, for example, by thermo and/or mechanicalbonding, such as thermo-sealing, ultrasonic bonding, such as ultrasonicwelding, an adhesive or adhesives, stitching or the like. The liquidbarrier sheet may be a breathable microporous film. The microporous filmmay be made of a material comprising at least two basic components,namely a thermoplastic elastomeric polyolefin polymer and a filler.These components and, in some embodiments, additional other componentsmay be mixed together, heated and subsequently extruded into amono-layer or multi-layer film using any one of various film-producingprocesses, such as cast embossed, chill and flat cast, and blown filmprocesses.

Regarding the choice of materials for the various layers in theabsorbent article, the materials may be chosen with consideration forthe bonding processes used when forming seals in between components ofthe absorbent article, such the seals in the sealed channels and theside seams. For example, if ultrasonic welding is chosen for joining theupper and lower core cover sides, the materials for the core cover maybe chosen such that they can form a secure bond during ultrasonicwelding, e.g. by at least one of the upper and lower side of the corecover comprising or consisting of thermoplastic polymer material.

The absorbent core 5, includes the absorbent component 50 and mayinclude further absorbent components such as components which provideliquid acquisition and liquid distribution. The absorbent core isdisposed between the topsheet 3 and the backsheet 4 to absorb theliquid, such as urine or other bodily fluids, which has passed throughthe topsheet 3. The absorbent component 50 may be a single-layerstructure or may be a layered structure, e.g. within the coherent area.The absorbent component 50 may comprise suitable amounts ofsuperabsorbent material. Such superabsorbent material is well known inthe field of absorbent articles and is constituted by a water-swellableand water-insoluble material which is capable of absorbing largequantities of fluid upon formation of a hydrogel. The absorbentcomponent may contain superabsorbent material in the form of fibers orparticles of absorbent polymer material. For example, the superabsorbentmaterial may be surface cross-linked, partially neutralizedpolyacrylates. The superabsorbent material, e.g., the superabsorbentfibers or particles, may be mixed with other absorbent or liquid uptakematerial or materials, such as cellulose fluff pulp, and/or arranged inpockets or layers in the absorbent component 50. The amount ofsuperabsorbent material and pulp in the absorbent component 50 may befrom 0 to 50 weight % pulp fibers and from 50 to 100 weight %superabsorbent material, or from 0 to 30 weight % pulp fibers and from70 to 100 weight % superabsorbent material.

The absorbent component 50 may further comprise components for improvingproperties of the absorbent core 5, such as core integrity and strength.For example, the absorbent component 50 may comprise a binder orbinders, such as binder fibers. Resilient fibers, chemically stiffenedfibers, etc. may be present in the absorbent component to counteractwet-collapse of cellulosic fibers. Such fibers may also be useful inretaining a fluid transporting capillary network in the absorbentcomponent so that absorbent fluid may be distributed in the absorbentcomponent and be absorbed by superabsorbent material also in parts ofthe absorbent component outside the initial wetting area of theabsorbent article.

The core cover 11,12 may be formed by a separate upper core cover 11layer and a separate lower core cover 12 layer. However, the disclosureis not limited to a core cover comprising two separate core coverlayers. The core cover 11,12 may also be made of one single materiallayer. The absorbent component 50 may be enclosed by one core cover11,12 layer which is folded in two and sealed along the open edges, ormay be enclosed by a continuous, tubular core cover sheet, therebyproviding upper 11 and lower core cover 12 sides for wrapping theabsorbent component 5 a,5 b,5 c. The basis weight of the core cover11,12 material may be in the interval of from 5 g/m² to 20 g/m². Thecore cover 11,12 material may be made of thermoplastic polymer material.The core cover material may be nonwoven material. The nonwoven materialmay be made of thermoplastic polymer material fibers or filaments. Thenonwoven layer may be formed by a variety of different processes, suchas spunbonding, airlaying, meltblowing or bonded carded web formationprocesses. The nonwoven layer may be made of an SMS(spunbond/meltblown/spunbond) or SS (spunbond/spunbond) nonwovenmaterial of polypropylene or bicomponent fibers of polypropylene andpolyethylene, or of a combination of such materials.

Furthermore, the various layers and components of the absorbent article1 may be attached by means of adhesive material, as known in the art.Such adhesive is not shown in the drawings.

One or more additional layers may be provided in the absorbent article1. For example, an acquisition layer may be arranged between theabsorbent component 50 and the topsheet 3. Such an additional layer mayfor example be in the form of an airlaid layer, a spunlace layer, ahigh-loft fiber material, an open-cell or perforated foam or any othertype of material layer or combination of layers which may be used in anabsorbent article to act as a liquid handling layer providing functionssuch as liquid acquisition, liquid absorption and liquid distribution. Aliquid acquisition layer is adapted to quickly receive and temporarilystore discharged liquid before the liquid can be absorbed by theabsorbent component. Such acquisition layer may be composed of forexample airlaid nonwoven, spunlace nonwoven, high loft nonwoven or foammaterials. An airlaid nonwoven may be produced wood pulp fluff fiberswhich are dispersed and suspended in a fast-moving air stream andcondensed onto a moving screen by means of pressure and vacuum.

With reference again to FIG. 1 , each sealed channel 9, 10 may have alength l₁ which corresponds to the longitudinal extension of the crotchportion 8. Each one of the sealed channels 9, 10 may have a length l₁which is between 5-50%, such as 10-50%, such as 28-38%, of the totallength l of the absorbent article 1. Furthermore, each sealed channel 9,10 may have a length l₁ which is between 10-60%, such as between 20-60%,such as between 30-50%, of the length of the absorbent component 50.

A further parameter is the positioning of the sealed channels 9, 10 inthe longitudinal direction of the absorbent article 1.

The position of the sealed channels 9, 10 in the longitudinal directionof the absorbent article 1 may be chosen so that each channel 9, 10terminates at a distance from the front end edge 19 of the article 1which is between 15-40%, such as between 22-25%, of the total length lof the article 1.

Furthermore, the topsheet may comprise at least one additive materialsuch as a skin care composition. The additive may be located on parts ofthe topsheet which are disposed along the longitudinal side edges 32, 33of the absorbent article 1 and/or along the longitudinal side edges 17,18 of the absorbent component 50. An advantage with such placement ofthe additive material, is that as the parts of the absorbent article 1which are arranged along the side edges normally will be closer to thebody of the wearer of the absorbent article 1 than a longitudinallycentral part of the absorbent article 1, the skin care benefits of theadditive may be obtained without the additive interfering with fluidacquisition through the topsheet 3 in the central part of the absorbentarticle 1.

FIGS. 2A-2G illustrate cores with absorbent components 50 havingdifferent combinations of features. The absorbent components 50 shown inthe examples of FIGS. 2A-2G should not be considered to be limiting tothe absorbent articles as disclosed herein, as it should be understoodthat one or more features of the coherent area 51 in any one of FIGS.2A-2G can be freely combined with features of the conformance zone 55 inany other of FIGS. 2A-2G.

The absorbent components 50 in FIGS. 2A-21 all have a conformance zone55. The conformance zone 55 comprises absorbent material and the zonemay comprise any of, or a combination of, the following: be without gapsor without areas being free from absorbent material; the absorbentmaterial in the conformance zone 55 may have a uniform or substantiallyuniform distribution of absorbent material; the absorbent material inthe conformance zone 55 may not comprise individual clusters ofabsorbent material having a diameter larger than 10 mm; the basis weightof the absorbent material in the conformance zone 55 may besubstantially uniform; the conformance zone 55 may comprise asubstantially homogenous mixture of superabsorbent material andcellulose fibers; the mixture of superabsorbents and cellulosic fibersin the conformance zone may have a basis weight coefficient of variationof at most 20%, as measured according to the method for measuring basisweight evenness provided in this disclosure.

The absorbent components 50 in FIGS. 2A-21 may be used in the absorbentarticle in FIG. 1 or in any other absorbent article as disclosed herein.

With reference to FIG. 2A, the coherent area 51 of the absorbentcomponent 50 is a layer of absorbent material having oblong high basisweight areas 60 arranged therein. The oblong high basis weight areas 60extend in the front portion of the coherent area 51, generally from thefront edge 52 of the coherent area 51 to the front ends of two sealedchannels 9, 10 which are arranged in the coherent area 51, as disclosedherein.

The sealed channels 9, 10 may optionally be supplemented by side sealsas disclosed herein. The conformance zone 55 has a rectangular shape andthe coherent area 51 and the conformance zone 55 are contiguous. Theabsorbent material in the conformance zone 55 has a basis weightgradient with a lower basis weight near the transverse back edge 22 ofthe absorbent component.

FIG. 3 shows a cross-section taken along the line III-III in the frontportion of the absorbent component 50 shown in FIG. 2A. The oblong highbasis weight areas 60 are shown as thickened regions of the absorbentcomponent 50. After formation of the absorbent component 50 in a formingmold, the absorbent component 50 will usually be compacted between twocompaction rolls.

FIG. 4 shows a cross-section taken along the line IV-IV in the crotchportion of the absorbent component 50 shown in FIG. 2A. The absorbentcomponent 50 which is shown has two longitudinally extending andgenerally straight sealed channels 9,10 in which the upper core coverside 11 is joined to the lower core cover side 12 by seals 9′, 10′extending along the sealed channels 9,10, at the bottom of the sealedchannels 9,10. The seals 9′, 10′ may be provided as bond linesconsisting of bonding elements arranged in a bond pattern. A width ofeach bond line may be less than a width of the corresponding sealedchannel 9, 10 in which the bond line is arranged. Thereby, a slack isformed in the core cover material between the edge of the bond line andthe edge of the sealed channel in which the bond line is placed. Suchslack may be provided to allow expansion room for the absorbent materialarranged on either side of the bond lines. The slack may be smaller onthe inner side of each sealed channel 9,10 which is facing towards thecentre of the absorbent article, and larger on the outer side of eachsealed channel 9,10 which is facing towards the side edges of theabsorbent article 1. The absorbent component 50 in the crotch portion 6has 51-90% of the total average basis weight of the absorbent materialin the absorbent component 50 in the front portion 6 of the absorbentarticle 1.

Furthermore, a central segment 13 is defined in the absorbent component50 between the sealed channels 9, 10. Two side segments 14 a, 14 b aredefined in the absorbent component 50 outside each sealed channel 9, 10,between the sealed channel 9,10 and a corresponding side seam 15, 16.Accordingly, the first side segment 14 a is positioned between the firstsealed channel 9 and a first side seam 15, whereas the second sidesegment 14 b is positioned between the second sealed channel 10 and asecond side seam 16. The side seams 15, 16 are configured for joiningthe upper core cover side 11 to the lower core cover side 12, suitablyby means of ultrasonic welding, heat sealing, or the like.

As shown in FIG. 4 , the absorbent component 50 is divided into acentral segment 13 located between the sealed channels 9,10 and two sidesegments 14 a, 14 b on either side of the central segment 13.

FIG. 5 shows a cross-section taken through the conformance zone 55 alongthe line V-V in FIG. 2A. The conformance zone 55 is shown to have auniform or substantially uniform distribution of absorbent material anddo not comprise individual clusters of absorbent material Theconformance zone 55 has 5-50% of the total average basis weight of theabsorbent material in the absorbent component 50 in the front portion 7of the absorbent article 1.

With reference to FIG. 2B, the coherent area 51 of the absorbentcomponent 50 is a layer of absorbent material having oblong high basisweight areas 60 arranged therein. The oblong high basis weight areas 60extend generally all the way from the front edge 52 of the coherent area51 to the back edge 53 of the coherent area 51.

Two sealed channels 9, 10 are arranged in the coherent area 51, asdisclosed herein. The sealed channels 9, 10 may optionally besupplemented by side seals as disclosed herein. The conformance zone 55is rectangular and comprises absorbent material and may not compriseareas free from absorbent material. The absorbent material in theconformance zone 55 has a lower basis weight than the absorbent materialin the high basis weight areas 60 in the coherent area 51. The coherentarea 51 and the conformance zone 55 are separated vertically by an area61 substantially free from absorbent material. The area substantiallyfree from absorbent material may have a basis weight of less than 200gsm, such as less than 100 gsm, such as less than 50 gsm, such as lessthan 10 gsm and may have a width of 2-30 mm, 2-20 mm such as 5-10 mm.

With reference to FIG. 2C, the coherent area 51 of the absorbentcomponent 50 is a layer of absorbent material having oblong high basisweight areas 60 arranged therein. The oblong high basis weight areas 60extend generally all the way from the front edge 52 of the coherent area51 to the back edge 53 of the coherent area 51. Two sealed channels 9,10 are arranged in the coherent area 51. The sealed channels 9, 10 mayoptionally be supplemented by side seals as disclosed herein. Theconformance zone 55 is rectangular and comprises absorbent material andmay not comprise areas free from absorbent material. The absorbentmaterial in the conformance zone 55 has a lower basis weight than theabsorbent material in the high basis weight areas 60 in the coherentarea 51. The coherent area 51 and the conformance zone 55 are separatedvertically by an area 61 substantially free from absorbent material. Thearea substantially free from absorbent material 61 in FIG. 2C is widerthan the corresponding area in FIG. 2B. The area substantially free fromabsorbent material may have a basis weight of less than 200 gsm, such asless than 100 gsm, such as less than 50 gsm, such as less than 10 gsmand may have a width of 2-30 mm, 2-20 mm such as 5-10 mm.

With reference to FIG. 2D, the coherent area 51 of the absorbentcomponent 50 is a layer of absorbent material having oblong high basisweight areas 60 arranged therein. The oblong high basis weight areas 60extend generally all the way from the front edge 52 of the coherent area51 to the back edge 53 of the coherent area 51. The high basis weightareas 60 of absorbent material alternate with low basis weight areas 54of absorbent material. The width of the coherent area 51 decreases in adirection towards the back edge 53 of the coherent area 51. Two sealedchannels 9, 10 are arranged in the coherent area 51. The sealed channels9, 10 may optionally be supplemented by side seals as disclosed herein.The conformance zone 55 has a square shape and comprises absorbentmaterial and may not comprise areas free from absorbent material. Theabsorbent material in the conformance zone 55 has a lower basis weightthan the absorbent material in the high basis weight areas 60 in thecoherent area 51. The coherent area 51 and the conformance zone 55 areseparated vertically by an area 61 substantially free from absorbentmaterial. The area substantially free from absorbent material may have abasis weight of less than 200 gsm, such as less than 100 gsm, such asless than 50 gsm, such as less than 10 gsm and may have a width of 2-30mm, 2-20 mm such as 5-10 mm.

With reference to FIG. 2E, the coherent area 51 of the absorbentcomponent 50 is a layer of absorbent material having oblong high basisweight areas 60 arranged therein. The oblong high basis weight areas 60extend generally all the way from the front edge 52 of the coherent area51 to the back edge 53 of the coherent area 51. Two sealed channels 9,10 are arranged in the coherent area 51. The sealed channels 9, 10 mayoptionally be supplemented by side seals as disclosed herein. Theconformance zone 55 is V-shaped and comprises absorbent material and maynot comprise areas free from absorbent material. The absorbent materialin the conformance zone 55 has a lower basis weight than the absorbentmaterial in the high basis weight areas 60 in the coherent area 51. Thecoherent area 51 and the conformance zone 55 are separated vertically byan area 61 substantially free from absorbent material. The areasubstantially free from absorbent material may have a basis weight ofless than 200 gsm, such as less than 100 gsm, such as less than 50 gsm,such as less than 10 gsm and may have a width of 2-30 mm, 2-20 mm suchas 5-10 mm.

With reference to FIG. 2F, the coherent area 51 of the absorbentcomponent 50 is a layer of absorbent material having oblong high basisweight areas 60 arranged therein. The oblong high basis weight areas 60extend generally all the way from the front edge 52 of the coherent area51 to the back edge 53 of the coherent area 51, i.e. in the front 6 andcrotch 8 portion of the absorbent article 1. Two sealed channels 9, 10are arranged in the coherent area 51. The sealed channels 9, 10 mayoptionally be supplemented by side seals as disclosed herein. Theconformance zone 55 is C- or D-shaped and comprises absorbent materialand may not comprise areas free from absorbent material. The absorbentcomponent 50 in the crotch portion 8 has 51-90% of the total averagebasis weight of the absorbent material in the absorbent component 50 inthe front portion 6 of the absorbent article 1. The conformance zone 55has 5-50% of the total average basis weight of the absorbent material inthe absorbent component 50 in the front portion 7 of the absorbentarticle 1. The coherent area 51 and the conformance zone 55 arecontiguous. The absorbent material in the conformance zone 55 has abasis weight gradient with a higher basis weight in a centrallongitudinal area of the conformance zone 55.

With reference to FIG. 2G, the coherent area 51 of the absorbentcomponent 50 is a layer of absorbent material having oblong high basisweight areas 60 arranged therein. The oblong high basis weight areas 60extend generally all the way from the front edge 52 of the coherent area51 to the back edge 53 of the coherent area 51. Two sealed channels 9,10 are arranged in the coherent area 51. The sealed channels 9, 10 mayoptionally be supplemented by side seals as disclosed herein. Theconformance zone 55 is W-shaped and comprises absorbent material and itdoes not comprise areas free from absorbent material. The absorbentmaterial in the conformance zone 55 has a lower basis weight than theabsorbent material in the high basis weight areas 60 in the coherentarea 51.

As disclosed herein, the absorbent article 1 may be provided withcomponents such as elastic barrier cuffs, elastic side panels, skin careagents, odour control material and other components which are commonlyused in absorbent articles such as for example baby diapers orincontinence garments. Such additional components are well known in theart and are not described in further detail here.

The disclosure may be varied within the scope of the appended claims.For example, the materials and dimensions used for the different layersforming the absorbent article 1 may be varied, as indicated above. Theabsorbent article may further include standing gathers, side panels,fastening systems etc. as known sealed channels 9, 10 in the art anddepending of the type of absorbent article intended.

Examples

Methods for Measuring Thickness, Basis Weight and Density

The absorbent core (including the core cover sheets) is carefullyseparated from the other diaper components. The core is then placed flatfor 24 hours in a laboratory environment conditioned to 23° C. and 50%relative humidity. Samples from the area of interest are then cut orpunched from the core (including the cover sheets). Thickness ismeasured under a pressure of 0.5 kPa. The thickness gauge foot shouldrest over the sample for about 5 seconds before reading the thicknessvalue. The sample is then weighed to the nearest milligram. The area ofthe sample can be determined with a ruler. In case the sample contoursare irregular, the sample can be photocopied or scanned, and the areacan be determined with a planimeter or suitable image analysis software.

The basis weight (g/m²) is then obtained by dividing the sample weightby the sample area. The density (kg/m³) is obtained according to theformula sample weight/(sample thickness×sample area).

In case individual samples from the area of interest (e.g. ridges orclusters) vary with regards to thickness, basis weight or density, alarge number of samples are measured to obtain a representative mean.

The total average basis weight of the absorbent material in theabsorbent component in the front portion of the absorbent article may bedetermined by measuring the total length of the core and then cuttingand weighing the front third of the length of the absorbent core. Theweight of the core covers should be subtracted. The basis weight (g/m²)is then obtained by dividing the sample weight by the sample area asdescribed above. The same determinations may be made for the absorbentcomponent in the crotch portion (middle third of the core) of the coreand the conformance zone (back third of the core).

Method for Measuring Basis Weight Evenness

For the evaluation, take five adjacent diapers from one and the sameconsumer package, or take five consecutively produced diapers fromproduction.

Unfold the diapers if folded, and lay bare for 48 hours in a stablelaboratory environment set to 23° C. and 50% relative humidity. Testingis performed in this same environment. Remove or neutralize all elasticelements in the diaper and place the diaper smooth and flat. Samples forevenness evaluation are then punched out from the diaper. The punchingtool has outer dimensions of 50×120 mm, with cutting cross bars every 20mm. The tool thus cuts 6 adjacent samples, each sample measuring 50×20mm (10 cm<2>). Two sets of 6 individual samples (12 samples in all) arecut from each diaper. Referring to FIG. 3 , one set of six samples istaken from the front region (Rf), and the other from the back region(Rb). The punching tool should be placed immediately outside the centralregion (Rc). The tool's length dimension coincides with the diaper'stransverse direction. The punching tool should be centered on thediaper's longitudinal centerline (C).

Determine the weight (to the nearest milligram) of each 50×20 mm coresample. For this purpose, any additional layers (such as the topsheet orthe backsheet) first must be subtracted. Take care so that nosuperabsorbent or significant amounts of fibers are lost when layingbare the core. Alternatively, the punched sample can be weighed as is.The basis weight of the additional layers then must be known beforehand(from the material specification or a separate determination), so thattheir weight can be subtracted from the samples. Calculate the basisweight (g/m<2>) for each sample from the large core:

(Sample weight (g))/(Sample area (0.001 m<2>))

Calculate the (arithmetic) mean basis weight (g/m<2>) for the series of60 samples, and then calculate the standard deviation for the series:

-   -   Image available on “Original document”    -   where x is the basis weight of the individual sample, x is the        arithmetic mean, and N is the number of samples (count 60).

Finally calculate the coefficient of variation (CV) by dividing thestandard deviation by the mean. Express the ratio in percent (%).

1. An absorbent article comprising an absorbent core sandwiched betweena liquid-permeable topsheet and a liquid-impermeable backsheet, thearticle having a longitudinal direction along a central longitudinalaxis (y1) and a transverse direction along a central transverse axis(x1) extending perpendicular to the longitudinal axis, (y1), theabsorbent article having a front end edge extending in the transversedirection and a back end edge extending in the transverse direction anda first side edge extending in the longitudinal direction and a secondside edge extending in the longitudinal direction, the absorbent articlecomprising a front portion, a back portion and a crotch portion locatedbetween the front portion and the back portion, wherein the absorbentcore comprises an absorbent component, the absorbent component beingenclosed by a core cover, the absorbent component comprising a coherentarea, the coherent area having an extension in the longitudinaldirection and is located only in the front portion and the crotchportion of the absorbent article and having an extension in thetransverse direction over a full width of the absorbent component insidethe core cover, the coherent area having a front edge and a back edge,wherein the absorbent component comprises oblong high basis weight areasof absorbent material alternating with oblong low basis weight areas ofabsorbent material, the high basis weight areas of absorbent materialand the low basis weight areas of absorbent material extending in thelongitudinal direction of the absorbent article at least in the frontportion, but not extending into the back portion, of the absorbentarticle, wherein the absorbent component in the crotch portion has51-90% of the total average basis weight of the absorbent material inthe absorbent component in the front portion of the absorbent article,and the core comprises a conformance zone with absorbent material in theback portion of the absorbent article having 5-50% of the total averagebasis weight of the absorbent material in the absorbent component in thefront portion of the absorbent article.
 2. Absorbent article accordingto claim 1, wherein the absorbent component in the crotch portion has55-85% of the total average basis weight of the absorbent material inthe absorbent component in the front portion of the absorbent articleand the conformance zone has 15-45% of the total average basis weight ofthe absorbent material in the absorbent component in the front portionof the absorbent article.
 3. Absorbent article according to claim 1,wherein the absorbent component in the crotch portion has 60% of thetotal average basis weight of the absorbent material in the absorbentcomponent in the front portion of the absorbent article and theconformance zone has 20% of the total average basis weight of theabsorbent material in the absorbent component in the front portion ofthe absorbent article.
 4. Absorbent article according to claim 1,wherein the oblong high basis weight areas have a width of from 3 mm to30 mm.
 5. Absorbent article according to claim 1, wherein the oblonghigh basis weight areas have a length to width ratio of from 2 to 135.6. Absorbent article according to claim 1, wherein the absorbentcomponent comprises 3 to 20 oblong high basis weight areas of absorbentmaterial alternating with oblong low basis weight areas.
 7. Absorbentarticle according to claim 1, wherein the total average basis weight ofthe of the absorbent material in the absorbent component in the frontportion of the absorbent article is 400 gsm.
 8. Absorbent articleaccording to claim 1, wherein the basis weight of the absorbent materialin the oblong low basis weight areas is 200 gsm or less.
 9. Absorbentarticle according to claim 1, wherein the longitudinal extension of theabsorbent component in the front portion of the absorbent article is20-40% of the longitudinal extension of the core, the longitudinalextension of the absorbent component in the crotch portion of theabsorbent article is 20-40% of the longitudinal extension of the coreand the longitudinal extension of the conformance zone is 20-40% of thelongitudinal extension of the core.
 10. Absorbent article according toclaim 1, wherein the absorbent component comprises at least oneabsorbent free channel extending in the longitudinal direction of theabsorbent component in the crotch portion of the absorbent article. 11.Absorbent article according to claim 1, wherein the conformance zonedoes not comprise areas being free from absorbent material. 12.Absorbent article according to claim 1, wherein the absorbent materialin the conformance zone does not comprise individual clusters ofabsorbent material having a diameter larger than 10 mm.
 13. Absorbentarticle according to claim 1, wherein the absorbent material in theconformance zone has a basis weight gradient with a lower basis weightnear the transverse back edge of the absorbent component.
 14. Absorbentarticle according to claim 1, wherein the absorbent material in theconformance zone has a basis weight gradient with a higher basis weightin a central longitudinal area of the conformance zone.
 15. Absorbentarticle according to claim 1, wherein the absorbent material in theconformance zone has a substantially uniform distribution of theabsorbent material.
 16. Absorbent article according to claim 1, whereinthe basis weight of the absorbent material in the conformance zone issubstantially uniform.
 17. Absorbent article according claim 1, whereinthe mixture of superabsorbents and cellulosic fibers in the conformancezone has a basis weight coefficient of variation of at most 20%, asmeasured according to the method for measuring basis weight evennessprovided in this disclosure.
 18. Absorbent article according to claim 1,wherein the conformance zone comprises a substantially homogenousmixture of superabsorbent material and cellulose fibers.
 19. Absorbentarticle according to claim 1, wherein the conformance zone issymmetrically orientated in relation to the longitudinal axis (y1) andwherein the conformance zone has a triangular shape, a D shape, a Wshape, a square or a rectangular shape.
 20. Absorbent article accordingto claim 1, wherein the core cover has an upper side and a lower side,the absorbent component comprising a sealing arrangement joining theupper and lower sides of the core cover, the sealing arrangementcomprising at least one sealed channel extending in the longitudinaldirection of the absorbent article, the sealed channel being free orsubstantially free from absorbent material.
 21. Absorbent articleaccording to claim 19, wherein the absorbent component comprises twosealed channels in the crotch portion of the absorbent article, thechannels extending in the longitudinal direction of the absorbentcomponent, wherein a central segment is defined in the absorbentcomponent between the sealed channels.
 22. Absorbent article accordingto claim 1, wherein the absorbent article is selected from disposableopen diapers, pant diapers and belted diapers.
 23. Absorbent articleaccording to claim 1, wherein the absorbent article is a disposableinsert which is worn inside a washable cover or support garment. 24.Absorbent article according to claim 22, wherein the article is forbabies and infants.